December 2020 Cover Lite blue.

qxp_4/06 Cover 11/8/20 10:44 AM Page C1

DECEMBER 2020
WELDING JOURNAL • VOLUME 99 NUMBER 12 • DECEMBER 2020

Equipping Essential
Workers

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
December 2020.qxp_Layout 1 11/6/20 3:41 PM Page 3

December 2020 • Volume 99 • Number 12 CONTENTS

FEATURES
28 The Heroes amongst Us
Recognizing the extraordinary efforts by many to 36
make masks, respirators, face shields, and more in
2020 — K. Campbell et al.

34 Wash Your Gloves and Fight the Spread of COVID-19

Just as we are expected to wash our hands, it’s
equally important to routinely wash our gloves
during the pandemic

36 Adjusting Safety Best Practices during a

Pandemic
This article covers the factors that have allowed
companies to persevere through COVID-19, the
importance of investing in technology for
enhanced safety, and training employees for the
future — J. Ziegenbein

THE AMERICAN WELDER

58 Brazers and Welders Craft Custom Copper
Lighting Fixtures 60
A Mississippi-based company is making
one-of-a-kind lanterns and chandeliers
C. Weihl

60 A Turnkey Turntable Brings Art to Life

A 40-ft bronze sculpture rotates on the Ashland,
Ky., riverfront thanks to custom fabricated
equipment — C. White

WELDING RESEARCH SUPPLEMENT

303-s Underwater Pulse-Current FCAW — Part 2:
Bubble Behaviors and Waveform Optimization
This study found that two different separation
modes can be adjusted by appropriately changing
the current values when the bubbles are necking
J. Wu et al.
312-s Filler Metal 16-8-2 for Structural Welds on
304H and 347H Stainless Steels for
High-Temperature Service
The purpose of this investigation was to explore
the potential application of Type 16-8-2 filler metal
for high-temperature structural welds in oil and gas
downstream applications — C. Fink et al.

DECEMBER 2020 / WELDING JOURNAL 3

December 2020.qxp_Layout 1 11/9/20 11:55 AM Page 4

DEPARTMENTS
5 Editorial 51 Section News
6 Press Time News 55 Guide to AWS Services
7 Washington Watchword 56 Personnel
8 News of the Industry The American Welder
12 COVID-19 Coverage 62 Learning Track
18 Arc-Tist Corner 66 Fact Sheet
20 Aluminum Q&A 81 WJ Index
22 Brazing Q&A 92 Product Listing
24 Product & Print Spotlight 95 Logos
40 Certification Schedule 97 Classifieds
41 Society News 98 Advertiser Index On the cover: Honoring the heroes
who changed operations to cope
47 Tech Topics with the pandemic this year.
Illustration by Rafael J. Amado,
graphic designer, AWS Education
Department.

OFFICERS WELDING JOURNAL

President Robert W. Roth
RoMan Manufacturing Inc.
Vice President W. Richard Polanin
WRP Associates
Vice President Dennis K. Eck
Praxair Distribution Inc.
Vice President Michael A. Krupnicki
Airgas USA
Treasurer Carey Chen
Incodema Inc. and Newcut Inc.
Executive Director & CEO Gary Konarska II
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
R. Ashelford (Dist. 13), Rock Valley College
T. Brosio (Dist. 14), Major Tool & Machine
D. E. Clark (Dist. 20), DEClark Welding Engineering PLLC
D. A. Desrochers (Dist. 1), Old Colony RVTHS
D. L. Doench (At Large), Hobart Bros. Co.
D. A. Flood (Past President), Consultant
K. R. Fogleman (Dist. 16), Consultant
M. Hanson (Dist. 15), Compass Electronics Solutions
R. E. Hilty (Dist. 7), Hilty Sign & Fabrication Co.
R. L. Holdren (At Large), ARC Specialties
T. S. Holt (Dist. 18), Tech Corr USA Management
J. Jones (Dist. 17), Coastal Welding Supply
D. H. Lange (Dist. 12), Northeast Wisconsin Tech. College
T. J. Lienert (Past President), T. J. Lienert Consulting LLC
S. Lindsey (Dist. 21), City of San Diego
S. M. McDaniel (Dist. 19), Big Bend Community College
S. Moran (Dist. 3), Philly Shipyard Inc.
R. Purvis (Dist. 22), Purvis Welding Inspection
S. Raghunathan (At Large), Saudi Aramco
H. Record (Dist. 5), Record Tool & Die
K. Shatell (At Large), Pacific Gas & Electric Co.
M. Sherman (Dist. 10), SW&E LLC
L. E. Showalter (Dist. 4), Newport News Shipbuilding
M. M. Skiles (Dist. 9), Consultant
W. J. Sperko (At Large), Sperko Engineering Services
R. H. Stahura (Dist. 6), ESAB Welding & Cutting Products
P. I. Temple (Dist. 11), Welding Consultant
H. W. Thompson (Dist. 2), Underwriters Laboratories Inc.
J. Thompson (Dist. 8), Wallace State Community College
Publisher/Editor Annette Alonso
Editorial
Managing Editor Kristin Campbell
Sr. Editor Cindy Weihl
Associate Editor Katie Pacheco
Associate Editor Alexandra Quiñones
Education Editor Roline Pascal
Peer Review Coord. Brenda Flores
Publisher Emeritus Jeff Weber
Design and Production
Managing Editor, Digital and Design Carlos Guzman
Production Manager Zaida Chavez
Assistant Production Manager Brenda Flores
Advertising
Senior Sales Executive, Corp. Sandra Jorgensen
Manager, Sales Operations Lea Owen
Subscriptions
Subscriptions Representative Sonia Aleman
saleman@aws.org
MARKETING ADVISORY COUNCIL
(MAC)
D. Doench, Chair, Hobart Brothers Co.
A. Sepulveda, Vice Chair, Hypertherm Inc.
D. Brown, Astaras Inc.
C. Coffey, The Lincoln Electric Co.
D. DeCorte, RoMan Mfg. Inc.
G. Konarska II, American Welding Society
D. Marquard, IBEDA Superflash Compressed
S. Molenda, ESAB Welding & Cutting
M. Muenzer, ORS Nasco
W. Newell Jr., Euroweld Ltd.
N. Schmid, Weiler Abrasives Group
S. Smith, Weld-Aid Products
D. Wilson, Wilson and Associates
C. Chen, Ex Officio, Incodema Inc. and Newcut Inc.
S. Fyffe, Ex Officio, Astaras Inc.
L. Kvidahl, Ex Officio, Ingalls Shipbuilding
T. Lienert, Ex Officio, Consultant
S. Moran, Ex Officio, Philly Shipyard Inc.
R. Polanin, Ex Officio, WRP Associates
R. Roth, Ex Officio, RoMan Mfg. Inc.
aws.org
8669 NW 36 St., # 130, Miami, FL 33166-6672
(305) 443-9353 or (800) 443-9353
AWS Promotes Diversity
AWS values diversity, advocates equitable and inclusive
practices, and engages its members and stakeholders in
establishing a culture in the welding community that
welcomes, learns from, and celebrates differences
among people. AWS recognizes that a commitment to
diversity, equity, and inclusion is essential to achieving
excellence for the Association, its members, and
employees.
Welding Journal (ISSN 0043-2296 Print) (ISSN 2689-0445
Online) is published monthly by the American Welding Society
for $120.00 per year in the United States and possessions,
$160 per year in foreign countries: $7.50 per single issue for
domestic AWS members and $10.00 per single issue for non-
members and $14.00 per single issue for international. Not
available for resale in either print or electronic form. American
Welding Society is located at 8669 NW 36 St., # 130, Miami, FL
33166-6672; telephone (305) 443-9353. Periodicals postage
paid in Miami, Fla. and additional mailing offices. POSTMASTER:
Send address changes to Welding Journal, 8669 NW 36 St.,
# 130, Miami, FL 33166-6672. Canada Post: Publications Mail
Agreement #40612608 Canada Returns to be sent to Bleuchip
International, P.O. Box 25542, London, ON N6C 6B2, Canada.
AWS Claims Policy: All hardcopy editions are shipped
FOB Origin. Publisher reserves the right to investigate and
make a determination on all claims submitted for missing
editions not received by a subscribing member or institution.
Any claim request determined to be valid will be fulfilled with
a digital copy of the edition. Publisher will NOT send any
hardcopy replacement issues for any reason.
Readers of Welding Journal may make copies of articles
for personal, archival, educational, or research purposes, and
which are not for sale or resale. Permission is granted to
quote from articles, provided customary acknowledgment of
authors and sources is made. Starred (*) items excluded from
copyright.
Copyright © 2020 by American Welding Society in both
printed and electronic formats. The Society is not responsible
for any statement made or opinion expressed herein. Data
and information developed by the authors of specific articles
are for informational purposes only and are not intended for
use without independent, substantiating investigation on the
part of potential users.

4 WELDING JOURNAL / DECEMBER 2020

Layout_A Manz Editorial WJ Dec 20 .qxp_Layout 1 11/6/20 5:24 PM Page 5

EDITORIAL

More Than 100 Years of Safety Practices

Safety and health teachings have been part of the American Welding Society (AWS)
since its very beginning. In its first publication, Journal of the American Welding Socie-
ty, released in October 1919, there was an article titled “Safe Practices for Gas Welding
and Cutting Equipment.”
Then, in January 1922, the first edition of Proceedings of the American Welding Soci-
ety, Vol. 1, No. 1, which would become the Welding Journal, was published. That publi-
cation featured several articles on safety and health. One was “Safeguarding the Oxy-
Acetylene Process” by J. L. Banash. The other was “A Paint That Will Not Reflect Ultra
Violet Rays” by W. S. Andrews. The AWS has followed the example of those safety pio-
neers ever since.

Fact Sheets Support Safety

August F. Manz
The AWS Safety and Health Committee has created more than 40 Safety and AWS Fellow
Health Fact Sheets on a wide range of subjects. The topics are as follows:

1. Fumes and Gases

“Safety and health
2. Radiation teachings have been
part of the American
3. Noise Welding Society (AWS)
since its very
4. Chromium and Nickel in Welding Fume beginning.”
5. Electrical Hazards

6. Fire and Explosion Prevention

7. Burn Protection

8. Mechanical Hazards

9. Tripping and Falling

10. Falling Objects

These Fact Sheets can be freely downloaded from aws.org/standards/page/safety-

health-fact-sheets. The Fact Sheets were written for the welding operator. The docu-
ments can be used for toolbox safety talks, teaching aids, personal use, and more.
These Fact Sheets are periodically revised and updated. Contact AWS Safety and
Health Secretary Steve Hedrick (steveh@aws.org) if you have a suggestion for another
Fact Sheet.

ANSI Z49.1 Offers Additional Protection Practices

Additionally, available from the AWS website is a free download of American Na-
tional Standards Institute (ANSI) Z49.1, Safety in Welding, Cutting, and Allied Process-
es. This document has been published by AWS since World War II and is considered
the Old Testament of welding safety. The U.S. Occupational Safety and Health Admin-
istration adapted its teachings in the Code of Federal Regulations, 29 CFR 1910 Subpart
Q, Welding, Cutting, and Brazing.
Stay safe; follow the safe practices taught by the AWS. WJ

DECEMBER 2020 / WELDING JOURNAL 5

Page 96 AWS Membership Renewal.qxp_FP_TEMP 11/5/20 3:52 PM Page 96
Kapco Feature – Dec.2020.qxp_Layout 1 11/6/20 1:37 PM Page 36

Adjusting Safety Best Practices

during a Pandemic
How companies can adapt to working in an BY JERRY ZIEGENBEIN

ever-changing COVID-19 environment

T
he COVID-19 pandemic has dif-
fering impacts on businesses of
all types across all industries. In
the manufacturing space, specifically,
it has influenced changes in the supply
chain, put extra pressure on suppliers
and partners, and prompted opera-
tions to take a close look at health and
safety protocols to ensure those prac-
tices are aligning with the findings and
advice of medical experts — Fig. 1.
As a result, companies have had to
quickly adapt to an ever-changing
COVID-19 environment. This article
highlights factors that allowed compa-
nies to endure the impact of the pan-
demic, the importance of investing in
technology that enhances employee
safety and productivity, and employee
training for the future.
Factors That Enabled
Companies to Endure the
Tough Times
The companies that have been most
successful in handling safety and
health considerations to keep opera-
tions running during the pandemic
were prepared to react quickly and
thoroughly from the start. Some of the
factors that positioned businesses well
to weather the initial months of the
pandemic include the following:
• Having extra inventory of sani-
tation materials and personal pro-
tective equipment (PPE). This in-
cludes products like hand sanitizer,
disinfecting cleaners, and face masks.
Organizations that were stocked up
for the traditional flu season benefit-

Fig. 1 — The COVID-19 pandemic has prompted manufacturers to bring a laser-like focus on safety, personal protective equipment,
sanitization, and personal hygiene in the workplace. Pictured is a Kapco Metal Stamping employee handing out face masks
amidst the COVID-19 pandemic.

36 WELDING JOURNAL / DECEMBER 2020

Kapco Feature – Dec.2020.qxp_Layout 1 11/6/20 1:38 PM Page 37
ted from being prepared. However, as
all companies operate under this new
normal for an unknown period of
time, it is best practice to make sure
your company is well stocked with san-
itization and safety materials. Other
sanitation practices that companies
embraced include spacing shift
changes by at least 30 min to ensure
the entire facility — shops, equip-
ment, bathrooms, and lunchrooms —
can be properly disinfected.
• Acting quickly and appropriate-
ly. When medical experts and epidemi-
ologists make recommendations,
companies should react appropriately,
even when those recommendations
change with new information — Fig. 2.
There is certainly a significant cost as-
sociated with making hard decisions
that change the norm of an operating
environment. However, companies
that reacted quickly to the facts and in-
formation related to the pandemic
made difficult choices, such as discon-
tinuing in-person department meet-
ings, customer and vendor visits, and
travel between internal offices and
business sites. Those interactions con-
tinued virtually unless absolutely nec-
essary, in which case appropriate mask
wearing and social distancing guide-
lines were followed. Employees in the
Fig. 3 — Skilled workers responsible for the welding and manufacture of products that organizations produce were supplied with
face masks and PPE while social distancing mandates were enacted.
Fig. 2 — Acting quickly and appropri-
ately to the recommendations of
medical experts is key to adapting to
a COVID-19 environment. Pictured is a
resource folder that all Kapco Metal
Stamping employees can access to
cope with the impact of COVID-19.
industry who were able to get their
jobs done remotely embraced the work-
from-home norm. Meanwhile, those
skilled workers responsible for the
welding and manufacture of many of
the products that companies produce
were supplied with face masks and PPE
while social distancing mandates were
enacted — Fig. 3.
• Maintaining a diverse set of
DECEMBER 2020 / WELDING JOURNAL 37
skilled workers. Organizations with a
diverse skill range of welders were able
to react swiftly at the onset of the pan-
demic. Take for example an organiza-
tion that may have seen initial de-
mand changes when the full realiza-
tion of the pandemic’s impact took
hold. By having welders with a diverse
skill range, organizations can toggle
output capacity without significant
layoffs due to the variety of roles and
responsibilities within their staff. Less
experienced welders can operate weld-
ing robots while more experienced
welders can assist those team mem-
bers with robot setups, programming,
inspections, and quality control. Addi-
tionally, the most experienced and
skilled welders can continue executing
manual welding work. That skill bal-
ance affords the flexibility to right-
size to meet demand without having
to change employment levels or adjust
hiring practices, even during times of
great uncertainty.
Investing in Employee Safety
and Productivity through
Technology
In typical times, it was already easy
to trace the investment of new tech-
Kapco Feature – Dec.2020.qxp_Layout 1 11/6/20 1:38 PM Page 38
Fig. 4 — Investing in technology and automation allows employees to focus more time and energy on following safety protocols
and health policies during the COVID-19 pandemic.
nology and equipment to improved
employee safety and increased effi-
ciency and productivity. To have the
organizational mindset and leadership
buy-in that adding new technology is
more than just about the financial in-
vestment can be a key difference mak-
er in developing a corporate culture
that is focused on excellence. It also
shows employees that the organiza-
tion wants them to have the very best
tools at their disposal.
Just before and during the COVID-
19 pandemic, Kapco Metal Stamping
(kapcoinc.com), a family-owned fabrica-
tion and stamping company located in
Grafton, Wis., actively invested in a
suite of welding technology. Each year,
the company sees 80-million lb of metal
through its facilities and performs cut-
ting, forming, joining, and finishing of
sheet and tube into numerous products.
The company’s investment in technolo-
gy played a pivotal role in it being able
to maintain production demand while
also keeping the welding team safe, so-
cially distanced, and healthy — Fig. 4.
Some of that equipment included a
pair of aluminum welding robots with
servo torches. These machines have
38 WELDING JOURNAL / DECEMBER 2020
minimized welders’ exposure to fumes
and physical repetitions, while also im-
proving quality consistency and pro-
duction rates. These robots feature
touch-sense capabilities that detect
any missing parts, which can eventual-
ly lead to expensive fixture repairs if
not caught immediately, not to men-
tion rework for the welding team.
Another intelligent welding system
provides preset programs to keep the
company compliant with customers’
requirements and ISO standards. It
also monitors arc-on time status and
wire usage. From a spot welding per-
spective, added bowl feeders and dual-
palm buttons helped the company
make improvements to pinch-point
safety and cycle times.
The other thing that should be
invested is time. Organizations that
are serious about safety should
perform daily safety audits to make
sure employees are using their
company-provided protective equip-
ment properly while following corporate
safety guidelines.
While you may look at that kind of
investment and think, “What does
that have to do with keeping my weld
team safe, healthy, and productive as it
relates to COVID-19?” These invest-
ments can help keep the team fresh
and focused. New technology and safe-
ty audits can help take the taxing, day-
to-day demands of their work off their
shoulders so they can spend their en-
ergy delivering quality work while also
keeping health and safety protocols
top of mind.
Training for Now, Training
for the Future
As demand for manufacturing has
rebounded, especially as manufactur-
ers look to source parts and compo-
nents domestically, it has prompted
many organizations to hire new
welders and robot operators. While re-
cruiting and retaining employees is a
challenge in and of itself, getting those
new hires in the door and trained is
pivotal for guiding their success as
good employees. It is also important
for making a new hire a safe and re-
sponsible team member in the current
COVID-19 environment that all organ-
izations are navigating.
Manufacturers should have robust
Kapco Feature – Dec.2020.qxp_Layout 1 11/6/20 1:39 PM Page 39
safety training in place as well as a cul-
ture around safety excellence. New
welder training should consist of at
least a week-long welding technology
and technique class for all new hires
immediately after corporate orienta-
tion, regardless of experience level. In
addition, if possible, organizations
dedicated to continuing excellence
should have an onsite welding trainer
who offers personalized instruction
for aluminum and steel; gas metal and
gas tungsten arc welding; and specific
equipment training. It’s also a good
practice to offer reimbursement for
American Welding Society Certified
Welding Inspector (CWI) and Certified
Welding Educator (CWE) seminars;
other training and testing; and desig-
nated, paid study time with experi-
enced CWIs on staff. This doesn’t just
go for manual welders. All robot tech-
nicians and engineers should have ba-
sic and advanced training in robotic
systems covered.
Having a welding team that is
trained to thrive will help to establish
a culture of excellence for safety, as
well as productivity and quality.
Conclusion
While the COVID-19 pandemic is
still evolving, we as manufacturers and
welding providers can come together
to help organizations strive toward
keeping employees healthy and busi-
ness strong.
That all starts with listening to ex-
perts and respecting the science of
what is known about the virus. If and
when new information comes to light,
have a conversation with your team
about how any additional findings can
be dealt with and what practices and
policies may be appropriate.
Meanwhile, when it comes to hav-
ing a robust inventory of sanitation
products and PPE on hand, if you need
it, it’s too late. If this pandemic has
taught us anything, it’s to always be
prepared with even the most basic
health and safety equipment — from
hand sanitizers to face masks.
Furthermore, if your organization is
considering an investment in new
technology and machinery, the pan-
demic may have pushed that possibility
to the forefront. Even if your bottom
DECEMBER 2020 / WELDING JOURNAL 39
line took a hit, big or small, this is the
time to make investments in improve-
ment. Not only could it help employees
work safer and smarter, it could also al-
low them to focus more of their energy
on following health protocols and elim-
inating the potential risk for a COVID-
19 outbreak in the facility.
Finally, there’s never been a better
time to hit refresh on training. Are you
requiring all new welders, regardless of
experience, to take mandatory train-
ing? Are you footing the bill for skills
development and training? Might it be
time to bring on a full-time trainer to
provide individualized coaching and
training? Or are there other potential
holes in your program?
Now is the time to update those
practices. Trained employees work
smarter, produce better, stay at your
organization longer, and help instill a
culture of excellence. WJ
JERRY ZIEGENBEIN
(ziegenbein@kapcoinc.com) is director of
weld operations, Kapco Metal Stamping,
Grafton, Wis.
Page 91 FABTECH.qxp_FP_TEMP 11/5/20 2:26 PM Page 91